Fatigue Fracture Investigation of Cemented Carbide Tools in Gear Hobbing, Part 2: The Effect of Cutting Parameters on the Level of Tool Stresses—A Quantitative Parametric Analysis

Gear Hobbing is a complex gear manufacturing method, possessing great industrial significance. The convoluted geometry of the cutting tools brings on modeling problems and is the main reason for the almost exclusive application of HSS as cutting material. However, despite its complicated kinematics, gear hobbing is sufficiently described by well-established software tools, which were presented in the first part of the present paper. Experimental investigations exhibited the cutting performance of cemented carbide cutting teeth, which were expected to be potential alternatives for massive hob production. In these cutting experiments, hardmetal tools exhibited in several cases early and unexpected brittle failures, which were interpreted by the FRSFEM model in the first part of the paper. This analysis indicated that the occurring dynamic stresses are the reason for the observed fatigue failures on the cemented carbide tools. The occurring stresses are highly dependent on the selection of cutting parameters and on the tool geometry. Therefore, the proper selection of the cutting data may prevent the early tool failures, as the dominant parameters for tool wear, allowing it to be worn out by the conventional abrasive mechanisms. Thus, the doubtless dominance of cemented carbide over the HSS tools, may be rendered. The present work illustrates a parametric analysis, which describes quantitatively the effect of various cutting and technological parameters on the stress level occurring in gear hobbing, with cemented carbide cutting teeth. Hereby, the optimization of the tool life is enabled, allowing the maximum exploitation of modern gear hobbing machine tools. Optimized gear hobbing with cemented carbide tools may be used, in order to introduce higher cutting speeds in massive gear production.

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Research of the Technological Parameters Influencing on the Surface Quality of Micro Complex Surface

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.291-292.513 ◽

2005 ◽

Vol 291-292 ◽

pp. 513-518 ◽

Cited By ~ 1

Author(s):

Ming Jun Chen ◽

Ying Chun Liang ◽

Ya Zhou Sun ◽

W.X. Guo ◽

Wen Jun Zong

Keyword(s):

Machine Tool ◽

Three Dimensional ◽

Complex Surface ◽

Cutting Parameters ◽

Numerical Control ◽

Tool Geometry ◽

Machining Accuracy ◽

Technological Parameters ◽

Machined Surface ◽

Machining Errors

In order to machine complex free surface parts, a micro NC (numerical control) three-dimensional machine tool is developed, integrated the PMAC control. Based on this NC machine tool, the influencing of the technological and tool’s parameters on machining accuracy of micro complex surface parts are analyzed, and the cause to lead to the machining errors is explained. Therefore, the cutting parameters and tool geometry parameters to machine micro complex surface, such as the human’s face, can be selected optimally. Finally, the micro complex human’s face is machined on this developed micro machine tool under optimal parameters. The experimental results show that the machined surface is smooth and continuous. The machined quality is satisfied.

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Machining Performance of TiAlN-Coated Cemented Carbide Tools with Chip Groove in Machining Titanium Alloy Ti-6Al-0.6Cr-0.4Fe-0.4Si-0.01B

Metals ◽

10.3390/met8100850 ◽

2018 ◽

Vol 8 (10) ◽

pp. 850 ◽

Cited By ~ 3

Author(s):

Zhaojun Ren ◽

Shengguan Qu ◽

Yalong Zhang ◽

Xiaoqiang Li ◽

Chao Yang

Keyword(s):

Surface Roughness ◽

Titanium Alloy ◽

Feed Rate ◽

Cutting Speed ◽

Cutting Parameters ◽

Cemented Carbide ◽

Machining Performance ◽

Cemented Carbide Tools ◽

Optimal Cutting Parameters ◽

Coated Cemented Carbide

In this paper, TiAlN-coated cemented carbide tools with chip groove were used to machine titanium alloy Ti-6Al-0.6Cr-0.4Fe-0.4Si-0.01B under dry conditions in order to investigate the machining performance of this cutting tool. Wear mechanisms of TiAlN-coated cemented carbide tools with chip groove were studied and compared to the uncoated cemented carbide tools (K20) with a scanning electron microscope (SEM) and energy dispersive spectrometer (EDS). The effects of the cutting parameters (cutting speed, feed rate and depth of cut) on tool life and workpiece surface roughness of TiAlN-coated cemented carbide tools with chip groove were studied with a 3D super-depth-of-field instrument and a surface profile instrument, respectively. The results showed that the TiAlN-coated cemented carbide tools with chip groove were more suitable for machining TC7. The adhesive wear, diffusion wear, crater wear, and stripping occurred during machining, and the large built-up edge formed on the rake face. The optimal cutting parameters of TiAlN-coated cemented carbide tools were acquired. The surface roughness Ra decreased with the increase of the cutting speed, while it increased with the increase of the feed rate.

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Analysys and Optimization of Exit Burr Size and Surface Roughness in Milling Using Desireability Function

Volume 3: Design, Materials and Manufacturing, Parts A, B, and C ◽

10.1115/imece2012-86201 ◽

2012 ◽

Cited By ~ 4

Author(s):

Seyed Ali Niknam ◽

Rene Kamguem ◽

Victor Songmene

Keyword(s):

Surface Roughness ◽

Desirability Function ◽

Cutting Parameters ◽

Burr Formation ◽

Tool Geometry ◽

Manufacturing Cost ◽

Burr Size ◽

Response Optimization ◽

Exit Burr ◽

Selection Of

The burr formation mechanism and surface quality highly depend on machining conditions. Improper selection of cutting parameters may cause tremendous manufacturing cost and low product quality. Proper selection of cutting parameters which simultaneously minimize burr size and surface roughness is therefore very important, as that would reduce the part finishing cost. This article aims to present an experimental study to evaluate parameters affecting the exit burr size (thickness and height) and surface roughness during milling of 6601-T6 aluminum alloy. Desirability function, Di(x), is then proposed for multiple response optimization. Optimum setting levels of process parameters are determined for simultaneous minimization of surface roughness and exit burr thickness and height. It was found that the changes in feed per tooth and tool geometry and coating have significant effects on variation of Di(x).

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Wear Behavior of Ti(N,C)-Al2O3 Coated Cemented Carbide Tools during Milling Ti2AlNb-Based Alloy

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.589-590.361 ◽

2013 ◽

Vol 589-590 ◽

pp. 361-365

Author(s):

Xiao Di Ma ◽

Jiu Hua Xu ◽

Wen Feng Ding ◽

Dong Sheng Lv ◽

Yu Can Fu

Keyword(s):

Wear Mechanisms ◽

Failure Modes ◽

Wear Behavior ◽

Cutting Speed ◽

Base Material ◽

Cutting Parameters ◽

Cemented Carbide ◽

Nickel Base ◽

Cemented Carbide Tools ◽

Coated Cemented Carbide

Ti2AlNb-based alloy is regarded as lightweight high-temperature structural material, which is expected to replace the nickel-base super alloy due to its low density, high elastic modulus, strength retention at elevated temperature, outstanding oxide resistance. However, these excellent properties also make Ti2AlNb to be difficult-to-cut material. In this paper, the milling experiment of Ti2AlNb alloy was carried out using Ti(N,C)-Al2O3 coated cemented carbide tools. SEM and EDS analysis was utilized to observe the worn tools to determine the tool failure modes and wear mechanisms. Tool life when milling Ti2AlNb was short and heavily dependent on the cutting parameters. During milling, coating material of the tool was separated rapidly from the base material. When the cutting speed exceeded 100m/min, serious cracks appeared on the tool surface. Thermal fatigue, adhesive and attrition were the predominant wear mechanisms of the coated tools.

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Experimental Research on Cutting Temperature of Cemented Carbide Tools during Cutting Austenitic Manganese Steel

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.413.347 ◽

2011 ◽

Vol 413 ◽

pp. 347-350

Author(s):

Gui Quan Han ◽

Zeng Zhi Zhang

Keyword(s):

Cutting Tools ◽

Cutting Temperature ◽

Cutting Speed ◽

Cutting Parameters ◽

Cemented Carbide ◽

Manganese Steel ◽

Dry Cutting ◽

Austenitic Manganese Steel ◽

Austenitic Manganese ◽

Cemented Carbide Tools

The cutting temperature rules of cemented carbide tools YW2 during cutting austenitic manganese steel ZGMn13 were investigated by experiments through systematically changing cutting parameters (cutting speed, feed, cutting depth) under the condition of dry cutting. The experiential expressions for cutting temperature of tools were summarized while dominating factors for influencing cutting temperature were analyzed. The results show that accounting values by experiential formulae basically match actually measuring values by experiments which may play an important role in studying cutting law of austenitic manganese steel. Cutting speed plays a major role in determining the temperature of cutting tools, followed by feed rate and depth of cutting.

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Study on the Cutting Performance of Micro Textured Tools on Cutting Ti-6Al-4V Titanium Alloy

Micromachines ◽

10.3390/mi11020137 ◽

2020 ◽

Vol 11 (2) ◽

pp. 137 ◽

Cited By ~ 2

Author(s):

Kairui Zheng ◽

Fazhan Yang ◽

Na Zhang ◽

Qingyu Liu ◽

Fulin Jiang

Keyword(s):

Surface Roughness ◽

Titanium Alloy ◽

Cutting Force ◽

Cutting Tools ◽

Cutting Speed ◽

Cutting Parameters ◽

Cutting Performance ◽

Cemented Carbide ◽

Feed Force ◽

Cemented Carbide Tools

Titanium alloys are widely used in various fields, but their machinability is poor because the chip would easily adhere to the tool surface during cutting, causing poor surface quality and tool wear. To improve the cutting performance of titanium alloy Ti-6Al-4V, experiments were conducted to investigate the effect of micro textured tool on the cutting performances. The cemented carbide tools whose rake faces were machined with line, rhombic, and sinusoidal groove textures with 10% area occupancy rates were adopted as the cutting tools. The effects of cutting depth and cutting speed on feed force and main cutting force were discussed based on experimental results. The results show that the cutting force produced by textured tools is less than that produced by non-textured tools. Under different cutting parameters, the best cutting performance can be obtained by using sinusoidal textured tools among the four types of tools. The wear of micro textured tools is significantly lower than that of non-textured tools, due to a continuous lubrication film between the chip and the rake face of the tool that can be produced because the micro texture can store and replenish lubricant. The surface roughness obtained using the textured tool is better than that using the non-textured tool. The surface roughness Ra can be reduced by 35.89% when using sinusoidal textured tools. This study is helpful for further improving the cutting performance of cemented carbide tools on titanium alloy and prolonging tool life.

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Cemented carbide tools in high speed gear hobbing applications

CIRP Annals ◽

10.1016/j.cirp.2017.04.016 ◽

2017 ◽

Vol 66 (1) ◽

pp. 117-120 ◽

Cited By ~ 6

Author(s):

B. Karpuschewski ◽

M. Beutner ◽

M. Köchig ◽

M. Wengler

Keyword(s):

High Speed ◽

Cemented Carbide ◽

Gear Hobbing ◽

Cemented Carbide Tools

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Fatigue Fracture Investigation of Cemented Carbide Tools in Gear Hobbing, Part 1: FEM Modeling of Fly Hobbing and Computational Interpretation of Experimental Results

Journal of Manufacturing Science and Engineering ◽

10.1115/1.1511172 ◽

2002 ◽

Vol 124 (4) ◽

pp. 784-791 ◽

Cited By ~ 24

Author(s):

A. Antoniadis ◽

N. Vidakis ◽

N. Bilalis

Keyword(s):

High Speed ◽

Cutting Tool ◽

Complex Geometry ◽

High Speed Steel ◽

Cutting Performance ◽

Cutting Process ◽

Cemented Carbide ◽

Fem Modeling ◽

Gear Hobbing ◽

Cemented Carbide Tools

Gear hobbing is a highly utilized flexible manufacturing process for massive production of external gears. However, the complex geometry of cutting hobs is responsible for the almost exclusive utilization of high-speed steel (HSS) as cutting tool material. The limited cutting performance of HSS, even coated HSS, restricts the application of high cutting speeds and restricts the full exploitation of modern CNC hobbing machine tools. The application of cemented carbide tools was considered as a potential alternative to modern production requirements. In former investigations an experimental variation of gear hobbing, the so-called fly hobbing was applied, in order to specify the cutting performance of cemented carbide tools in gear production. These thorough experiments indicated that cracks, which were not expected, might occur in specific cutting cases, leading to the early failure of the entire cutting tool. In order to interpret computationally the reasons for these failures, an FEM simulation of the cutting process was developed, supported by advanced software tools able to determine the chip formation and the cutting forces during gear hobbing. The computational results explain sufficiently the failure mechanisms and they are quite in line with the experimental findings. The first part of this paper applies the verified parametric FEM model for various cutting cases, indicating the most risky cutting teeth with respect to their fatigue danger. In a step forward, the second part of the paper illustrates the effect of various technological and geometric parameters to the expected tool life. Therefore, the optimization of the cutting process is enabled, through the proper selection of cutting parameters, which can eliminate the failure danger of cemented carbide cutting tools, thus achieving satisfactory cost effectiveness.

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